JP2009161352A - Graphite tape supply and backing paper take-up device - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a graphite compound tape supply and backing paper take-up device capable of using a large tape supply reel and a breadthwise wide tape. <P>SOLUTION: This device for supplying one or more strands of a relatively wide tape to a high speed graphite tape laminating machine may include tape supply reels 14L and 14T and backing paper take-up reels 16L and 16T turnably mounted on the machine, dancer rollers 22L and 22T mounted on the machine for lateral movement thereon, and a mechanism for actively controlling rotation of the tape supply and backing paper take-up reels 14L. 14T, 16L and 16T and lateral movement of the dancer rollers 22L and 22T relative to a support flame 18 so that respective tensions in the tapes are maintained substantially constant during both of an on the fly tape adding operation and an on the fly tape cutting operation of the laminating machine. <P>COPYRIGHT: (C)2009,JPO&INPIT

Description

  The present invention relates generally to tools used in the manufacture of composite structures, and in particular allows for the use of large tape supply reels and substantially wide tapes, thereby laminating for use with high speed composite tape laminating machines. The present invention relates to a graphite composite tape supply and a backing paper winding device for realizing a high lamination speed and a low material price in the process.

  For example, the demand for large complex composite parts such as those used in aircraft composite bodies is growing rapidly. These parts typically have parallel strips of unidirectional graphite fiber tape impregnated with a composite tape, for example, a non-cured resin ("prepreg"), placed on each other on a forming tool and then the resin Manufactured by curing. Increasing demand is typically met by suppliers by one of the following two methods: 1) purchase of many current technology stacking machines, or 2) development of machines capable of stacking parts at higher speeds. The development of the second method, the high speed lamination machine, can actually reduce the cost of tooling, equipment and equipment in the long run.

  The existing tape supply method relies on a relatively narrow tape that is all “parallel wound” on a long spool in the same way that a wire is wound on a fishing line reel to which a reciprocating claw is attached. The tape width is limited to 1.27 cm (0.5 inch) for parallel winding of the material. The diameter of the reel must be substantially increased to accommodate the useful amount of tape present there, and thus has an unacceptably high inertia, so narrow tapes are in the motion picture film method. Cannot be "one roll" onto a corresponding width reel.

  A "dancer", or secondary roller, adjacent to the spool on which the tape is pulled from the spool, is usually used to absorb the impact applied to the tape, and the brake acting on the spool is used to decelerate the spool. Used to absorb the inertia. Existing methods use active control of braking force applied to the supply spool and passive control of dancer movement. Since existing methods do not actively control the position of the dancer, it is very difficult to control a large supply reel with variable inertia.

  Thus, existing solutions are limited to methods using spools wound in parallel with laminated tape that is limited to a maximum width of 1.27 cm (0.5 inch). The total number of tape strips that the laminating machine can handle when placing a strip of tape is limited, and the use of narrow tapes reduces the total strip width, thereby laminating components with relatively large areas. Requires multiple passes of the machine stacking head over the layup tool. Therefore, a high lamination speed can be achieved if multiple strips of wide strips of tape can be used reliably.

  Therefore, there is a need in the industry for an apparatus that allows a composite tape laminating machine to reliably load a large number of tapes having a large width, thereby realizing a substantially increased laminating speed.

  According to the present invention, the graphite composite tape supply and backing paper take-up device allows a substantially large tape supply reel and a substantially wide tape to be used reliably in the machine, and a high lamination speed in the lamination process. And is given to be used with composite tape laminating machines that realize low material prices.

  In one exemplary embodiment, the apparatus includes a supply reel that is rotatably mounted, a take-up reel that is disposed adjacent to the supply reel and is rotatably mounted, and a side with respect to the supply and take-up reel. A dancer roller that is mounted for movement, a rotatable compression roller that is adapted for rolling motion on the surface of the workpiece, and a rotationally mounted disposed between the dancer roller and the laminating head A peeling roller and a lamination head. The first and second strands that are bonded together are wound around a supply reel. The first strand has an outer end extending from the supply reel around the dancer roller and the release roller, below the compression roller. The second strand extends from the supply reel around the dancer roller and the release roller and has an outer end coupled to the core of the take-up reel. An apparatus is provided for actively controlling the rotation of the supply and take-up reels and the lateral movement of the dancer roller, whereby at least a first movement of the compression roller over the surface of the workpiece and subsequent cutting of the first strand. The tension of one strand is kept substantially constant.

  In another exemplary embodiment, the method provides a rotatably mounted supply reel having a tape with first and second strands that are bonded to be wound together, adjacent to the supply reel. A winder reel mounted in a rotatable manner, a dancer roller for lateral movement with respect to the supply and take-up reel, a rotary compression roller for rolling motion on the surface of the workpiece, and a dancer A rotatable peeling roller is mounted between the roller and the compression roller, and the outer end of the first strand extends from the supply reel around the dancer roller and the peeling roller and below the compression roller. Extend the outer end of the second strand from the supply reel around the peeling roller and wind it up The pressure side of the first strand is adhered to the surface of the workpiece by rolling the compression roller over the surface of the workpiece, the second strand is cut during the period of movement of the compression roller, and fed and wound. Actively controlling the rotation of the take-up reel and the lateral movement of the dancer roller, so that at least the first strand tension is applied during the operation of the compression roller on the surface of the workpiece and the subsequent cutting of the first strand. Includes steps that are kept constant.

1. A supply reel;
A take-up reel arranged adjacent to the supply reel;
A dancer roller mounted for lateral movement with respect to the supply and take-up reels;
A compression roller adapted for rolling motion on the surface of the workpiece;
A peeling roller disposed between the dancer roller and the lamination head;
First and second strands that are bonded together and wound on a supply reel, the first strand being around the dancer roller and the peeling roller and below the compression roller, an outer end extending from the supply reel A second strand extending around the dancer roller and the peeling roller from the supply reel and having an outer end coupled to the core of the take-up reel;
Actively controlling the rotation of the supply and take-up reels and the lateral movement of the dancer roller, so that at least the first strand during the movement of the compression roller on the surface of the workpiece and the subsequent cutting of the first strand And a mechanism for maintaining a substantially constant tension.

  2. The apparatus of claim 1, wherein the tape is wound once on a supply reel.

  3. The apparatus according to claim 2, wherein the second strand has an opposite surface coated with a release agent, and the release property of the release agent on one side is stronger than the release property of the release agent on the other side.

  4). The apparatus of claim 1 wherein the first strand comprises a matrix of graphite fibers impregnated with an uncured resin.

  5). The apparatus of claim 1 wherein the apparatus feeds the first strand to the lamination head with its adhesive surface facing the workpiece direction.

6). The first strand tension control mechanism is:
A sensor for sensing a lateral position of the dancer roller and generating a signal corresponding to the position;
An actuator coupled to the dancer roller and operable to move the dancer roller laterally in response to a signal generated by the sensor;
A brake acting on the supply reel and operable to brake rotation of the supply reel in response to a signal generated by the sensor;
The apparatus of claim 1, further comprising a tensioning device operable on the take-up reel and operable to maintain the tension of the second strand substantially constant.

  7. The apparatus of claim 6, wherein the sensor comprises a proximity sensor located in the actuator.

  8). The apparatus of claim 6, wherein the actuator comprises a pneumatic actuator.

9. The device is disposed on the support frame to guide the compression roller across the surface of the workpiece during the movement period;
The second is positioned adjacent to the first device such that it follows the compression roller during its movement across the surface of the workpiece and is laterally offset from the preceding device by the width of the first strand. The apparatus according to claim 1, comprising two apparatuses.

  10. A tape laminating machine for aircraft manufacture, to which the apparatus according to claim 1 is attached.

  11. A tape laminating machine to which the apparatus according to claim 9 is attached.

12 In a method of feeding a tape having first and second strands to a laminating machine during a laminating period for a second strand of workpieces.
Mounting the apparatus of claim 1 on a support frame of the laminating machine;
Supply tape from the supply reel to the stacking head of the stacking machine,
After being peeled from the tape, the second strand is wound up by a winding reel,
Rolling the compression roller over the surface of the workpiece so that the adhesive surface of the first strand is adhered to the surface;
Cutting the second strand during the operation of the compression roller;
Controlling the rotation of the supply and take-up reels and the lateral movement of the dancer roller with respect to the support frame, whereby at least the first strand tension is applied to the operation of the compression roller on the surface of the workpiece and the subsequent first step. A method which is maintained substantially constant during the cutting of one strand.

13. And further providing a rotatably mounted supply reel having a tape comprising wound and bonded first and second strands;
A rotatable take-up reel is mounted adjacent to the supply reel;
Install a rotatable dancer roller for lateral movement on the supply reel and take-up reel,
Install a rotatable compression roller for rolling motion on the surface of the workpiece,
Install a rotatable peeling roller between the dancer roller and the compression roller,
The outer end of the first strand extends from the supply reel around the dancer and release rollers and below the compression roller;
An outer end of a second strand extends from the supply reel around the peeling roller and the dancer roller and is coupled to the core of the take-up reel;
Rolling the compression roller over the surface of the workpiece so that the adhesive surface of the first strand is adhered to the surface;
Cutting the second strand during the period of movement of the compression roller;
Actively controlling the rotation of the supply and take-up reels and the lateral movement of the dancer roller, thereby at least a first time during the movement of the compression roller on the surface of the workpiece and the subsequent cutting of the first strand. And maintaining the tension of the second strand substantially constant.

14 The rolling of the compression roller is
Pasting the outer end of the first strand to the first position on the workpiece by the compression roller;
Rolling the compression roller over the surface of the workpiece to peel the tape from the supply reel;
14. The method of claim 13, including the step of pressing the adhesive surface of the tape against the surface of the workpiece by the compression roller during the period of movement of the compression roller on the workpiece.

  15. The method of claim 14, wherein the cutting of the first strand comprises cutting the first strand at a second location on the workpiece.

  16. The method of claim 13, wherein the tape is wound once on the supply reel.

  17. 15. The method of claim 14, wherein pressing the adhesive surface of the first strand to the surface of the workpiece supplies tape to the compression roller with an adhesive surface facing the surface of the workpiece.

18. Control of the rotation of the supply and take-up reel and the lateral movement of the dancer roller
Senses the side position of the dancer roller and generates a signal corresponding to the position;
Move the dancer roller to the side in response to the signal,
Braking the rotation of the supply reel in response to the signal;
14. The method of claim 13, including the step of rotating the take-up reel after peeling from the tape to maintain the tension of the second strand substantially constant.

19. In an apparatus that supplies graphite tape to a high-speed graphite tape lamination machine,
A tape supply reel rotatably mounted on a support frame of the lamination machine;
A backing paper take-up reel rotatably attached to the support frame adjacent to the tape supply reel;
A dancer roller mounted for lateral movement on the support frame;
A peeling roller rotatably mounted between the dancer roller and the lamination head;
A strand of graphite tape wound in parallel on the supply reel;
Actively controlling the rotation of the tape supply and backing paper take-up reel and the lateral movement of the dancer roller with respect to the support frame, so that during both the tape application and tape cutting operations of the laminating machine, A mechanism for maintaining the tension of the tape substantially constant,
The tape has a backing paper that adheres to its adhesive surface, and an outer end that extends from the supply reel to the lamination head of the lamination machine around the dancer roller and the peeling roller,
The backing paper has an outer end that extends from the supply reel around the dancer roller and the peeling roller and is connected to the core of the take-up reel;
The peeling roller moves the tape and the backing paper in different directions by the movement of the tape and the backing paper on the peeling roller, thereby applying tension to the adhesive surface between the tape and the backing paper, and the take-up reel An apparatus configured to peel the backing paper from the tape for wrapping.

20. The apparatus is disposed on a support frame to guide the lamination head across the surface of a workpiece during movement of the lamination head;
During the movement period, a compression roller is placed across the surface of the workpiece and is positioned adjacent to the first device such that it is laterally offset from the preceding device by the width of the first strand. The apparatus of claim 1 comprising a second apparatus.

  22. Furthermore, each comprises a leading and trailing device, each offset laterally with respect to each other, whereby the laminating machine has a plurality of parallel and laterally contacting graphite tapes in a single pass over the surface of the compression roller. 21. The apparatus of claim 20, wherein the apparatus is capable of being simultaneously laminated to the surface of the workpiece.

23. In a method of winding graphite paper to a laminating machine and winding a backing paper bonded to the adhesive surface of the tape during the laminating period of the tape to the workpiece,
Mount a rotatable tape supply reel on the support frame of the laminating machine,
A rotatable backing paper take-up reel is mounted on the support frame adjacent to the tape supply reel,
Install the dancer roller on the support frame for the lateral movements related to it,
Wrap the strand of tape with the backing paper glued around the supply reel once,
The outer end of the tape extends from the supply reel around the dancer roller of the laminating machine and below the compression roller;
A rotatable peeling roller is mounted between the dancer roller and the compression roller so that movement of the tape and backing paper on the peeling roller causes the tape and backing paper to move in different directions, whereby the tape and Apply tension on the adhesive surface between the backing papers, peel the backing paper from the tape to wind it on the take-up reel,
Before the tape reaches the lamination head, the peeling paper is peeled from the tape by the peeling roller,
Winding the backing paper onto a take-up reel,
Affixing the adhesive surface of the outer end of the tape to the first position on the surface of the workpiece by the compression roller,
Rolling the compression roller over the surface of the workpiece to pull the tape from the supply reel;
During the movement period of the compression roller on the workpiece, the pressure surface of the tape is pressed against the surface of the workpiece by the compression roller;
Cutting the tape at a second position on the surface of the workpiece during operation of the compression roller;
Active control of rotation of the tape supply and backing paper take-up reel and lateral movement of the dancer roller with respect to the support frame, thereby allowing the tape during both the tape application and tape cutting operations of the lamination machine. A method comprising the step of maintaining a substantially constant tension.

24. The laminating machine further includes a first and a second plurality of tape feeding and backing paper take-ups, each of which is laterally offset from each other by the width of the tape and is arranged to precede and follow the compression roller, respectively. Reel, dancer roller, peeling roller, compression roller,
24. The method of claim 23 including laminating a plurality of parallel and laterally contacting graphite tapes on the surface of the workpiece in a single pass over the surface of the compression roller.

  The foregoing and numerous other features and advantages of the apparatus of the present invention will be better understood upon consideration of the following detailed description of exemplary embodiments thereof, particularly when considered in this manner in conjunction with the accompanying drawings. be able to. Similar reference numbers are used to refer to similar elements in the respective drawings.

1 is a partial front view of an exemplary embodiment of a graphite tape feeding and backing paper take-up device according to the present invention attached to a graphite tape lamination machine and shown adjacent to the lamination head. FIG. FIG. 2 is a cross-sectional view of the top surface of the exemplary device of FIG. 1 when viewed along a cutting line extending through the respective centers of the leading and trailing tape supply and backing paper take-up reels of the device. 2 is a functional block diagram of an exemplary tape supply and backing paper take-up unit of the exemplary apparatus of FIG. FIG. 3 is a process flow diagram illustrating successive steps in an exemplary embodiment of a method for supplying graphite tape to a tape lamination machine during a lamination process according to the present invention. FIG. 3 is an enlarged partial front view of the pre-feed reel and associated take-up reel of the exemplary apparatus shown during steady state tape lamination operation. FIG. 6 is another enlarged partial front view of the supply and take-up reel of FIG. 5 shown immediately after the “cut” operation and before the “append” operation. FIG. 10 is another enlarged partial front view of the advance supply and take-up reel shown during the add-on operation. FIG. 6 is an enlarged partial front view of the advance feed and take-up reel of FIG. 5 showing the operation of the dancer of the device after a cutting operation. FIG. 3 is a flowchart of an aircraft manufacturing and service method. Aircraft block diagram.

  An exemplary embodiment of a graphite tape supply and backing paper take-up device according to the present invention is shown in the partial front view of FIG. FIG. 2 is a cross-sectional view of the exemplary apparatus 10 when viewed along the section line taken in FIG. FIG. 3 is a functional block diagram of an exemplary tape supply and backing paper winder of the apparatus of FIGS.

  As can be seen with reference to FIGS. 1-3, the exemplary apparatus 10 includes a pair of graphite tape supply reels 14L and 14T and an associated pair of backing paper take-up reels 16L and 16T, which are tapes. Mounted on the support frame 18 of the stacking machine for independent rotation in the direction of arrow DR associated with each reel 14L, 14T, 16L, 16T, respectively, during the stacking process.

  During the laminating process, the laminating machine (not shown) including its tape laminating head 12 is shown in FIG. 1 in the direction of arrow DT, ie the left side of the drawing with respect to the workpiece (not shown) located under the laminating head 12. Can move to. During this exercise period, the graphite tape 20L and 20T strands or “tows” with backing paper 30L and 30T to be bonded respectively are pulled out from the supply reels 14L and 14T, respectively, and then passed over the respective dancer rollers 22L and 22T. Each passes over “peeling” rollers 24L and 26T. When the respective strands 20L and 20T pass on the peeling rollers 24L and 24T, the respective backing papers 30L and 30T are peeled off from the respective strands 20L and 20T and wound around the take-up reels 16L and 16T, respectively. The strands 20LS and 20TS, i.e. the graphite tape peeled from their respective backing papers 30L and 30T, then pass over the respective guide rollers 26L and 26T and then under the respective compression rollers 28L and 28T of the laminating head 12 pass. The compression rollers 28L and 28T of the laminating head 12 press the respective adhesive surfaces S of the tape strands against the surface of the workpiece as the laminating head 12 of the machine passes in the direction of the arrow DT.

  When the passing of the lamination head 12 over the workpiece is finished, the respective strands of tape 20LS and 20TS can be cut "on the fly", i.e. while the lamination machine is in motion. After the cutting operation, the laminating machine is lifted with respect to the workpiece and rotated horizontally at a selected angle, for example 40 °, 90 °, 135 °, 180 °, and lowered to the workpiece. The next pass can be made by the machine on the workpiece in another direction, for example in the opposite direction to the first pass, ie the right side of FIG.

  In the configuration described above, the supply and backing paper take-up reels 14L and 16L and other related components located to the left of the lamination head 12 in the drawing always “precede” the lamination head 12 when the tape is loaded. , Referred to herein as the “preceding” component of the device 10, and the component on the right side of the stacking head 12 is always “following” the head and hence the “following” component of the device.

  Further, as shown in the top cross-sectional view of FIG. 2, in the illustrated embodiment, the subsequent components 14T, 16T, 20T, 22T, 24T, 26T, and 28T of the apparatus 10 are the corresponding ones of the tapes 20L and 20T. Can be offset laterally with respect to the direction of movement DT of the laminating machine relative to the preceding component of the apparatus with a pitch equal to one width. As a result, the strands of the graphite tapes 20LS and 20TS are placed on the workpiece at the same time in a parallel and side-by-side relationship. Thus, the laminating machine places multiple strands of tape 20LS and 20TS simultaneously on the workpiece in a single pass or swath. As further shown in FIG. 2, the laminating machine has an additional set 14L, 16L, 22L, 24L of both leading and trailing tape feeding and backing paper winding components that extend laterally with similar spacing or pitch. , 26L, 28L and 14T, 16T, 22T, 24T, 26T, 28T. For example, in the particular exemplary embodiment shown, the device 10 comprises five additional sets 14L, 16L, 22L, 24L, 26L, 28L and 14T, 16T, 22T, 24T, 26T, 28T. So that the laminating machine can simultaneously place 12 parallel contacting strips or swaths of tape 20LS and 20TS on the workpiece in one pass of the machine across the workpiece.

  The graphite tape 20 used in the laminating machine can be composed of a matrix of unidirectional graphite fibers embedded or impregnated in a type of uncured resin, sometimes referred to as a “prepreg”. Since the resin is not cured, it is sticky or feels sticky. In order to maintain the adhesiveness, the tape is manufactured by adhering the liner of the backing paper 30 to one side of the tape for the purpose of facilitating processing. The backing paper 30 is provided with release agents having different strengths on the opposite surface, that is, the peeling ability is stronger on the other side than on one side of the backing paper. A difference in adhesive strength is provided for the graphite tape 20, whereby the tape can be wound on a supply reel. The tape then peels off easily from the reel, i.e. does not adhere to the next inner layer of the tape, but the backing is still peeled off while adhering to one side of the graphite tape, referred to herein as the "sticky" side of the tape Can do. The backing paper is bonded until just before the tape is applied to the workpiece to maximize the adhesive properties of the adhesive side of the tape.

  Therefore, it is necessary to remove and store the backing paper 30 before applying the tape 20 to the workpiece. In order to store the backing paper after removal, each supply reel 14L and 14T of the apparatus 10 is provided with an associated backing paper take-up reel 16L and 16T arranged adjacent to it. As shown in the process flow diagrams of FIGS. 1 and 4, at S1, the supply reels 14L and 14T are loaded with graphite tapes 20L and 20T, respectively, and the respective protective backing paper 30L adhered to them. The loaded supply reels 14L and 14T have 30T and are mounted on the laminating machine along with their respective backing paper take-up reels 16L and 16T.

  At S2, the respective outer ends of the tapes 20L and 20T are passed around the respective dancer rollers 22L and 22T and around the respective peeling rollers 24L and 24T. Each backing paper 30L and 30T is then peeled from their respective tapes 20L and 20T by peeling rollers 24L and 24T. At S3, each outer edge of the backing paper is then coupled to the core of the backing paper take-up reel. Tapes 20LS and 20TS, i.e., the outer ends of the graphite tape from which their respective backing paper has been peeled, are passed through respective guide rollers 26L and 26T, after which the respective compression rollers 28L and 28T of the laminating head 12 Threaded down.

  The peeling rollers 24L and 24T are configured so that the movement of each tape 20L and 20T and their adhesive backing paper 30L and 30T on the peeling rollers 24L and 24T can move in different directions. Yes. In other words, the tapes and their respective backing papers are pulled away from each other by respective release rollers 24L and 24T. Changes in the relative movement between the tape and their respective backings create tension, which can act on the adhesive surface between the tape and their respective backings, thereby causing each backing paper roll to later. The backing paper is peeled off from their respective tapes so that they are wound on take-up reels 16L and 16T.

  Therefore, during the laminating operation, the tapes 20L and 20T are pulled out from their respective reels 14L and 14T and pass over the respective dancer rollers 22L and 22T and then pass over the respective peeling rollers 24L and 24T. At this point, as shown in FIG. 1, the respective backing papers 30L and 30T are peeled from the respective tape strands and wound on the backing paper take-up reels 16L and 16T of the apparatus. The graphite tape strands 20LS and 20TS then move to the corresponding guide rollers 26L and 26T and the subsequent compression rollers 28L and 28T, respectively. The adhesive side of the tape (indicated by S in the drawing) previously protected by the backing paper 30L and 30T is arranged to be substantially exposed for application to the workpiece by the respective compression rollers 28L and 28T. .

  As shown in the process flow diagram of FIG. 4, the lamination process includes two steps S4 and S5. These steps can include relatively abrupt acceleration and deceleration of the graphite tape and thus the associated tape supply reels 14L, 14T and backing paper take-up reels 16L, 16T. These steps can be referred to as a tape “add” step S4 and a tape “cut” step S5.

  In an additional step S4, the laminating head 12 of the laminating machine, in particular the compression rollers 28L and 28T, is moved a short distance above the workpiece. Prior to addition, the ends of the tapes 20LS and 20TS can be placed a short distance from the compression rollers 28L and 28T. The feeding of the tape can be started just before lowering the head when the end of the tape is aligned perpendicular to the first position on the workpiece, eg, the end where passage can be initiated. The compaction rollers 28L and 28T are then lowered onto the workpiece, whereby the compaction roller attaches the adhesive surfaces at the ends of the tapes 20LS and 20TS to the workpiece. The addition is done "on the fly", i.e. while the laminating machine and the head 12 are moved relative to the workpiece. The machine containing the tape feeder 10 can be moved at high speed onto the workpiece in the direction of the arrow DT in FIG. 1, so that the compression roller has the adhesive surface “S” of multiple strands of tape 20LS and 20TS. The workpiece is pressurized and the tape strand is adhered thereto. During the additional step, the tapes 20L and 20T can be forcibly detached from the respective supply reels 14L and 14T by the movement of the machine across the workpiece, i.e. with the supply reels 14L and 14T. The tension of the tape can therefore be accelerated and therefore the tension of the laminating head 12 needs to be accurately controlled to prevent the rollers of the laminating head 12 from sliding on the tape, causing damage or adversely affecting the accuracy of the addition. Since the addition is done on the fly (ie the laminating machine does not stop on the workpiece at the addition position), the timing of the addition and the tension of the tape needs to be controlled very consistently.

  Passage can be terminated when the compression rollers 28L and 28T pass a second position of the workpiece, eg, the second edge on the opposite side. At the end of the pass, the tape addition step ends and the cutting process S5 can be started. During the cutting process, each knife (not shown) quickly cuts the tape 20LS and 20TS on the fly, ie while the tape is still moved and coincides with the second position of the workpiece. Can be done. During the cutting process, the tapes 20LS and 20TS and thus the respective supply reels 14L and 14T can be decelerated very rapidly. As previously mentioned, the respective tensions of tapes 20LS and 20TS therefore need to be carefully managed to prevent undesired results.

  Those skilled in the art will recognize that it is necessary to maintain precise control of the tension of the graphite tapes 20LS and 20TS during both the addition and cutting processes to obtain an accurate and reliable high speed lamination process. Let's go. The exemplary apparatus 10 described herein can be adapted to provide such precise control. In addition, the apparatus can use unprecedented 3.8 cm (1.5 inch) wide graphite tape 20 wound around supply reels 14L and 14T, but is not limited to these widths, and other tape widths may be used. It can be used effectively as well.

  The apparatus 10 of the present invention can therefore be particularly suitable for supplying large quantities of material required for high speed lamination. When laminating the outer parts, a plurality of narrow swaths of material can be placed in one pass as described above. This process is referred to herein as “fiber placement”. One of the difficulties in fiber placement experienced by conventional lamination equipment is to control the feeding of a large number of individual tapes. The tape may be cut and / or over other undesired conditions, especially when maintaining the proper tension of the tape during lamination to prevent tape bridging in the sharp profile during the loading period. Run. The apparatus 10 can supply graphite tapes 20L and 20T that are consistently oriented from respective supply reels 14L and 14T. The apparatus can remove and collect each backing paper 30L and 30T with each separate take-up reel 16L and 16T. The apparatus actively operates the dancer rollers 221L and 22T, the supply reel brake systems 32L and 32T, and the backing paper take-up reel tension device 34L configured to accurately manage the tape tension and reel inertia in the manner described below. And 34T can be controlled. The apparatus can therefore provide a reliable means of supplying multiple swaths of relatively wide graphite tape 20 to a laminating machine using high speed on-the-fly tape course addition and cutting.

  Device 10 manages the movement of dancers 22L and 22T and uses simple on / off active control to provide adequate suppression of supply reels 14L and 14T, which can be independent of stacking speed or reel inertia Can do. As previously mentioned, tape supply spools used by existing methods can increase the cost of materials. In existing methods, the graphite tape or “slit material” is first removed from the backing paper and a thin plastic “replacement” backing film is then reapplied to the tape before it is wrapped around the spool core. As previously mentioned, the apparatus 10 of the present invention uses tapes 20L and 20T with the original backing paper 30 still attached, thereby eliminating the need for a replacement backing film. Another drawback of the prior art means is that a large number of parallel wound spools required with a wide stack swath width are now stacked side by side as in the apparatus 10 shown in FIGS. 1 and 2, for example. It requires a much wider width than the supply reels 14L and 14T with large diameter and narrow width.

  As shown in FIG. 1, the apparatus 10 is more than three times larger than the relatively wide tapes 20L and 20T, a 1.27 cm (0.5 inch) wide tape where the prior art tape feeders are limited. Can be designed to receive a single supply reel 14L, 14T around which a tape having a width of 5 is wound. In one embodiment of the supply device 10 of the present invention, each dancer 22L and 22T can be provided on a respective linear guide 40L and 40T on the supply frame 18. Each pneumatic actuator 36L and 36T can apply a respective force to dancers 22L and 22T through respective push rods 38L and 38T. Simple on / off control can change the force applied to each dancer 22L and 22T from a low value to a high value. This simple and active control mechanism stops the supply reels 14L and 14T without slack in the tapes 20L and 20T during on-the-fly cutting, and the dancers 22L and 22T on-the-fly. Add to ensure that you are in the best position. A properly positioned dancer can be applied without excessively high tension on the tape, which can cause tape damage or inaccurate course start, and cutting can be achieved without tape overrun. To be able to

  Therefore, during the steady-state stacking period, pneumatic dancer biasing cylinders 36L and 36T, backing paper take-up and tensioning devices 34L and 34T, and the brake force applied to the supply reels 14L and 14T by the respective reel brakes 32L and 32T are compressed respectively Rollers 28L and 28T can be combined to keep the tape 20LS and 20TS tension low and consistent. Excess tension on the compression rollers 28L and 28T can also cause bridging with step changes in the contour of the workpiece forming tool (not shown).

  The device 10 can also support a stack with all adhesive surfaces down. As described above, the surface “S” of the graphite tape 20 adhered to the backing paper 30 shows a larger adhesive force than the surface exposed to air and light for an arbitrary length of time. Inspection of the device 10 proved that the laminating performance can be improved if all the tapes are oriented in one direction, in other words if the adhesive surface “S” is facing down. As described above, the exemplary structure shown in FIGS. 1 and 2 can allow the laminating machine to place all of the swath graphite tape with the adhesive side down. Accordingly, the preceding supply reel 14L can be wound in one turn by the backing paper 30L facing inward (“paper inside”) and the subsequent reel 14T facing outward (“paper outside”). Can be rolled up with paper 30T. Instead of simply mirroring the position of the backing paper take-up reels 16L and 16T, these take up backing paper 30L and 30T facing inward and outward, respectively, when the respective tape 20L and 20T feeds toward the laminating machine Each can be positioned as shown in FIG.

  Importantly, the device 10 of the present invention is capable of performing the active control required to use the large high inertia supply reels 14L and 14T that can be wound on a relatively wide tape. is there. As previously mentioned, existing means are limited to the use of a parallel spool spool of 1.27 cm (0.5 inch) wide tape. The apparatus 10 can thus provide the basic elements of a lamination system that can have a low material cost and a substantially high lamination rate.

  FIG. 5 is an enlarged partial front view of a portion of the apparatus 10 showing only the pre-feed reel 14L and its associated take-up spool 16L during the steady state tape stacking operation. As shown in FIG. 5, the tape 20L is redirected around the dancer roller 22L first before proceeding to the lamination head 12 of the lamination machine. As the tension of the tape 20L, a force directed to the right in the drawing can be generated in the dancer carriage 42L. The tension of the pneumatic cylinder 36L can generate a force on the carriage 42L that can only partially balance the tension of the tape directed leftward. During steady state stacking periods, the pneumatic biasing cylinder 44L coupled to the brake lever 46L can be de-energized to selectively apply high braking force to the rim of the supply reel 14T, thereby integrating the The brake lever compression springs are low and generate a substantially constant braking force on the supply reel. The braking force can generate a controlled tension on the moving tape 20L. The tape tension can thereby hold the dancer roller 22 in a fully expanded position, as shown in FIG. As described above, when the tape 20L passes over the peeling roller 24L of the laminating machine, the backing paper 30L is peeled from the tape 20L. The backing paper 30L can absorb some of the tension present on the upstream tape 20L of the roller 24L, and the remaining controlled tension of the tape 20LS extends to the compression roller 28L (not seen in FIG. 5).

  FIG. 6 is an enlarged partial front view of the preceding supply reel 14L and backing paper take-up reel 16L portion of the apparatus 10 of FIG. 5 showing a state in which the additional operation is prepared immediately after the cutting operation S5. When the tape 20L is cut, the pneumatic dancer biasing cylinder 36L can be switched to a high contraction force, which causes the actuator biasing rod 38L to move the dancer carriage 42L and the dancer as shown in FIG. 22L is retracted to the left with respect to the supply frame 18. This movement of the dancer 22L can wind up the slack of the tape 20L when the supply reel 14L decelerates due to the constant traction force applied by the reel brake 32L as described above. A signal generated by a sensor 37 configured to sense the position of the dancer 22L relative to the actuator 36L when the cylinder 36L contracts about 80% of its total travel of the dancer 22L. Is used to urge the high-pressure pneumatic brake cylinder 44L as described above, thereby quickly suppressing the rotation of the supply reel 14L.

  FIG. 7 is an enlarged partial front view of the pre-feed reel 14L and backing paper take-up reel 16L portion of the apparatus 10 of FIG. 5 during the additional operation period. At the start of the addition, the force applied by the pneumatic biasing cylinder 36L on the dancer 22L can be reduced to a low setting. The tension on the tape 20L can then move the dancer 22L to the right as indicated by the large arrow DT in FIG. Minimizing the tension applied to the tape 20L during the loading period can improve the accuracy and consistency of the starting point.

  8A and 8B show enlarged portions of the preceding supply reel 14L and the backing paper take-up reel 16L of the apparatus 10 of FIG. 5 after the cutting operation S5 in which the supply reel 24L can be prevented from rotating. FIG. While laminating material on the workpiece and during the period when the repositioning moves, the laminating machine head 12 is shown below as shown in FIG. 8A or shown in FIG. 8B. Shake up like you are. After the cutting S5, the reel brake 32L prevents the supply reel 14L from rotating. The swinging motion of the head 12 shown in the drawing can change the length of the tape between the supply reel 14L and the head 12, so that the dancer 22L has a constant tape tension during the swinging motion of the laminated head 12. Can move properly to keep constant. Therefore, as shown in FIGS. 8A and 8B, the rotation of the head 12 during the lamination period can affect the feeding speed of the tape 20L. The rotation of the head 12 can move the dancer 22L when the supply reel 14L is stationary. Accordingly, the dancer 22L is not fully contracted during the cutting period, thereby allowing any loose tape to be wound immediately after cutting.

  According to the exemplary embodiment described herein, apparatus 10 can provide important features of a high speed tape lamination machine. Current spool-based machines using parallel wound tapes of 1.27 cm (0.5 inch) width cannot achieve higher stacking speeds than machines with larger supply reels wound with wider tape. . Thus, the device 10 helps advance tape lamination technology to a high level that reduces tooling, equipment, materials, and equipment prices.

  With particular reference to the drawings, embodiments of the present invention may be described in the context of the aircraft manufacturing and service method 900 shown in FIG. 9 and the aircraft 902 shown in FIG. During the pre-manufacturing period, exemplary method 900 may include aircraft 902 specifications and design 904 and material procurement 906. During manufacturing, component 908 and system integration 910 of aircraft 902 components and subassemblies are performed. Thereafter, aircraft 902 can be validated and delivered at 912 for use at 914 for service. In service by the customer, the aircraft 902 is scheduled for daily maintenance and operation 916 (which may also include deformation, reconfiguration, refurbishment, etc.).

  Each process of method 900 may be performed or performed by a system integrator, a third party, and / or an operator (eg, a customer). For purposes of this description, the system integrator may include, but is not limited to, any number of aircraft manufacturers and major system subcontractors, and the third party is not limited to any number of sellers, subcontractors, and supplies. Operators can be included, and operators can include airlines, leasing companies, military organizations, service organizations, and the like.

  As shown in FIG. 10, an aircraft 902 manufactured by the exemplary method 900 can include a fuselage 918 with multiple systems 920 and an interior 922. Examples of high-level systems 920 include one or more propulsion systems 924, electrical systems 926, hydraulic systems 928, and environmental systems 930. Any number of other systems can be included. Although an aerospace example has been shown, the principles of the present invention can be applied to other industries such as the automotive industry.

  The apparatus and method implemented herein can be used during any one or more stages of manufacturing and operating method 900. For example, a component or part assembly corresponding to the manufacturing process 908 can be manufactured in a manner similar to the component or part assembly that the aircraft 902 is manufactured in service. Also, one or more apparatus embodiments, method embodiments, or combinations thereof may be used during manufacturing stages 908 and 910, for example, by substantially facilitating assembly or reducing the price of aircraft 920. Can do. Similarly, one or more apparatus embodiments, method embodiments, or combinations thereof may be used while the aircraft 902 is operating to perform maintenance and operations 916, for example, but not limitation.

  Those skilled in the art will recognize that many variations, substitutions, and variations can be made in the application and practice of the tape feeding and backing paper winding apparatus of the present invention without departing from the scope of the present invention. In this regard, the technical scope of the present invention is not limited to the technical scope of the specific embodiments shown and described herein, which are merely a few examples thereof, but the scope of the following claims and functional equivalents. It must correspond well to the technical scope.

Claims (15)

A supply reel;
A take-up reel arranged adjacent to the supply reel;
A dancer roller mounted for lateral movement with respect to the supply and take-up reels;
A compression roller adapted for rolling motion on the surface of the workpiece;
A peeling roller disposed between the dancer roller and the lamination head;
First and second strands that are bonded together and wound on a supply reel, the first strand being around the dancer roller and the peeling roller and below the compression roller, an outer end extending from the supply reel A second strand extending around the dancer roller and the peeling roller from the supply reel and having an outer end coupled to the core of the take-up reel;
Actively controlling the rotation of the supply and take-up reels and the lateral movement of the dancer roller, so that at least the first strand during the movement of the compression roller on the surface of the workpiece and the subsequent cutting of the first strand And a mechanism for maintaining a substantially constant tension.   The apparatus of claim 1, wherein the tape is wound once on a supply reel.   The apparatus according to claim 2, wherein the second strand has an opposite surface coated with a release agent, and the release property of the release agent on one side is stronger than the release property of the release agent on the other side.   The apparatus of claim 1 wherein the first strand comprises a matrix of graphite fibers impregnated with an uncured resin.   The apparatus of claim 1 wherein the apparatus feeds the first strand to the lamination head with its adhesive surface facing the workpiece direction. The first strand tension control mechanism is:
A sensor for sensing a lateral position of the dancer roller and generating a signal corresponding to the position;
An actuator coupled to the dancer roller and operable to move the dancer roller laterally in response to a signal generated by the sensor;
A brake acting on the supply reel and operable to brake rotation of the supply reel in response to a signal generated by the sensor;
The apparatus of claim 1, further comprising a tensioning device operable on the take-up reel and operable to maintain the tension of the second strand substantially constant.   The apparatus of claim 6, wherein the sensor comprises a proximity sensor located in the actuator.   The apparatus of claim 6, wherein the actuator comprises a pneumatic actuator. The device is disposed on the support frame to guide the compression roller across the surface of the workpiece during the movement period;
The second is positioned adjacent to the first device such that it follows the compression roller during its movement across the surface of the workpiece and is laterally offset from the preceding device by the width of the first strand. The apparatus according to claim 1, comprising two apparatuses. And further providing a rotatably mounted supply reel having a tape comprising wound and bonded first and second strands;
A rotatable take-up reel is mounted adjacent to the supply reel;
Install a rotatable dancer roller for lateral movement on the supply reel and take-up reel,
Install a rotatable compression roller for rolling motion on the surface of the workpiece,
Install a rotatable peeling roller between the dancer roller and the compression roller,
The outer end of the first strand extends from the supply reel around the dancer and release rollers and below the compression roller;
An outer end of a second strand extends from the supply reel around the peeling roller and the dancer roller and is coupled to the core of the take-up reel;
Rolling the compression roller over the surface of the workpiece so that the adhesive surface of the first strand is adhered to the surface;
Cutting the second strand during the period of movement of the compression roller;
Actively controlling the rotation of the supply and take-up reels and the lateral movement of the dancer roller, thereby at least a first time during the movement of the compression roller on the surface of the workpiece and the subsequent cutting of the first strand. And maintaining the tension of the second strand substantially constant. The rolling of the compression roller is
Pasting the outer end of the first strand to the first position on the workpiece by the compression roller;
Rolling the compression roller over the surface of the workpiece to peel the tape from the supply reel;
11. The method of claim 10, including the step of pressing the adhesive surface of the tape against the surface of the workpiece by the compression roller during the period of movement of the compression roller on the workpiece.   The method of claim 11, wherein the cutting of the first strand comprises cutting the first strand at a second location on the workpiece.   The method of claim 10, wherein the tape is wound once on the supply reel.   The method of claim 11, wherein pressing the adhesive surface of the first strand to the surface of the workpiece supplies tape to the compression roller with an adhesive surface facing the surface of the workpiece. Control of the rotation of the supply and take-up reel and the lateral movement of the dancer roller
Senses the side position of the dancer roller and generates a signal corresponding to the position;
Move the dancer roller to the side in response to the signal,
Braking the rotation of the supply reel in response to the signal;
11. The method of claim 10 including the step of rotating the take-up reel after peeling from the tape to maintain the tension of the second strand substantially constant.

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